Assembling electrical connecting device to cordage

ABSTRACT

In order to assemble modular plugs, comprised of two mating dielectric parts and plural blade-like terminals, to each end of a jacketed telephone cord, an operator positions each unfinished end of a length of cordage in a transfer device and then initiates the operation of an assembly apparatus. The transfer device transfers each end of the cord to a workholder while mating dielectric parts are fed separately to each of two assembly positions and in vertical alignment with a horn and anvil of ultrasonic bonding facilities. One of the parts in each assembly position is supported on the anvil while the other part is held in the horn. Each of the workholders is turned rotatably to move the cordage end held therein into the assembly position and into vertical alignment with the spaced apart portions of the modular plug. The jacket is removed from the end portions of the cord to expose the individually insulated conductors whereafter the anvil is moved upwardly to position the conductors in conductor-receiving troughs in the one part. Simultaneously, the horn is lowered to engage the other part with the one part and bond the parts together. The blake-like terminals are moved upwardly through the anvil and into terminal-receiving grooves in the one part and into electrical engagement with the conductors. Excess lengths of the conductors are severed and together with the stripped jacket are removed. The workholders are returned to initial positions and cammed open to release the plugged cord ends and permit the finished cord to drop into a receptacle.

"United States Patent [191 Adams et al.

[ July 22, 1975 ASSEMBLING ELECTRICAL CONNECTING DEVICE TO CORDAGE [75]Inventors: George Phillip Adams; Frederick David Gavin, Jr.; AnthonyPete Natale, all of Baltimore, Md.

[73] Assignee: Western Electric Company,

Incorporated, New York, NY.

[22] Filed: Aug. 27, 1974 [21] Appl. No.: 501,007

[52] US. Cl. 29/628; 29/203 R; 29/203 S; 29/630 R; 29/630 A; 228/1 [51]Int. Cl. H01R 43/00 [58] Field of Search 29/628, 629, 630 R, 630 A,29/203 R, 203 P, 203 S, 206, 208 R, 208 E,

208 F, 33 R, 33 M, 203 D, 203 DT, 203 DS; 81/9.5l, 9.5 R;228/1, 13, 44,47

[57] ABSTRACT In order to assemble modular plugs, comprised of twomating dielectric parts and plural blade-like terminals, to each end ofa jacketed telephone cord, an operator positions each unfinished end ofa length of cordage in a transfer device and then initiates theoperation of an assembly apparatus. The transfer device transfers eachend of the cord to a workholder while mating dielectric parts are fedseparately to each of two assembly positions and in vertical alignmentwith a horn and anvil of ultrasonic bonding facilities. One of the partsin each assembly position is supported on the anvil while the other partis held in the horn. Each of the workholders is turned rotatably to movethe cordage end held therein into the assembly position and intovertical alignment with the spaced apart portions of the modular plug.The jacket is removed from the end portions of the cord to expose theindividually insulated conductors whereafter the anvil is moved upwardlyto position the conductors in conductorreceiving troughs in the onepart. Simultaneously, the horn is lowered to engage the other part withthe one part and bond the parts together. The blake-like terminals aremoved upwardly through the anvil and into terminal-receiving grooves inthe one part and into electrical engagement with the conductors. Excesslengths of the conductors are severed and together with the strippedjacket are removed. The workholders are returned to initial positionsand cammed open to release the plugged cord ends and permit the finishedcord to drop into a receptacle.

15 Claims, 38 Drawing Figures CORD TRANSFER POSITION PATENTEDJUL 22 ms 38 95 434 SHEET 56 CORD TRANSFER POSITION F/G. 2B

PLUG ASSEMBLY 5 POSITIONII w 56 PLUG A EMBLY POSI N I' PATENTEDJUL 22 msSHEET KEHHW/ F/G. ZJ

PATENTEDJUL 22 ms SHEET ASSEMBLY ASSEMBLY POSITION II POSITION IPATENTEnJuLzz I975 V 3,895,434

CORD TRANSFER POSITION CORD INPUT POSITION /04- Liam SHEET PATENTEDJUL22 1975 SHEET ZOFEWOR fimpzmmmxx 03 5 PATENTED JUL 2 2 ms SHEETASSEMBLING ELECTRICAL CONNECTING DEVICE TO CORDAGE BACKGROUND OF THEINVENTION 1. Field of the Invention This invention relates to assemblingelectrical connecting devices to cordage, and more particularly, tomethods of and apparatus for providing telephone cords with modularplugs which may be inserted by a subscriber into a jack in a telephonehandset.

2. Technical Considerations and the Prior Art In the field of individualsubscriber telephone station equipment, there have been some recentadvances which increases subscriber flexibility for product replacement.Specifically, telephone cords, both line and retractile, are now beingequipped with miniature plugs which are capable of being inserted by acustomer into telephone handsets specially provided with mating jacks.In like manner, a customer may readily disconnected the line or springcord or both from the telephone handset. The innovations are part of abroad improvement in telephone cords referred to as modularity.

Modularity permits replacement of cords by the customer for reasons ofstyle change or to simply replace worn cords. The savings in time andcosts should be readily apparent. Modular plugs and jacks are disclosedand claimed in US. Pat. Nos. 3,699,498 and 3,761,869 issued in the namesof E. C. Hardesty, C. L. Krumreich, A. E. Mulbarger, Jr. and S. W.Walden.

Because of the miniature dimensions of the elements of the plug, forexample, it is beneficial to provide apparatus which may be used toexpeditiously assemble the plugs. This is especially true with respectto the assembly of miniature terminal blades with a dielectric housing.Apparatus for accomplishing this assembly is disclosed and claimed in acopending application Ser. No. 346,556, filed Mar. 30, 1973, now Pat.No. 3,839,787 in the names of W. B. Brown, deceased, and F. D. Gavin andassigned to the assignee of the present invention.

The success of the modularity program also depends in part on thecapability of providing apparatus for assembling the modular miniatureplugs to each end of a retractile cord. Such an apparatus may includethe apparatus of the hereinbefore referred to Brown-Gavin applicationfor inserting terminal blades into the dielectric housing and intoelectrical engagement with the conductors comprising the cord.

Priorly, with the advent of the modularity program, the assembly of theplugs to the cords was accomplished manually. An operator would stripthe cord jacket from an end portion of the cord to expose the nyloncovered tinsel conductors. At another station, another operatorpositions two dielectric parts, which comprise the housing, inultrasonic bonding facilities and positions the end portion of the cordin engagement with one of the parts so that the conductors are receivedin conductor-receiving troughs formed therein. Next, the other one ofthe plastic parts is bonded ultrasonically to the one part to completethe housing and enclose the parts after which the excess lengths of theconductors are severed at a third work station. Subsequently, at afourth work station an operator inserts each plug into a cavity andcauses apparatus, such as that disclosed and claimed in the Brown- Gavinapplication Ser. No. 346,556, filed Mar. 30,

1973, now Pat. No. 3,839,787, operated to insert terminal bladesthereinto.

Clearly, this highly manual method of assembly involves undesirablyseveral unnecessary steps. A method of assembling cords to plugs whichcould be implemented by automatic machinery would be most beneficial.

SUMMARY OF THE INVENTION With these and other objects in mind, thisinvention contemplates inserting each end portion of an unfinished cordinto a transfer device which is caused to transfer each end portion intosecuring engagement with a workholder. The workholder is moved toposition the free cord end in an assembly position in alignment with twospaced parts which when assembled comprise a dielectric housing. Then aportion of the jacket of each end portion of the cord is removedpartially therefrom and a lower one of the parts moved into engagementwith the cord end while the portion of the jacket maintains the exposedportions of the conductors in a spaced relationship to facilitate thebonding of the other one of the parts to the one part after whichblade-like terminals are inserted into the one part into electricalengagement with the cord conductors. Ecxess ends of the conductors areremoved and the cord end with the dielectric housing and the terminals,which comprise a plug, attached to the cord are returned to an initialposition and ejected from the workholder.

More particularly, methods and apparatus are provided for assemblingminiature electrical connectors in the form of plugs to each end of aretractile or line telephone cord. An operator causes each end of thecord to be clamped in a transfer device and then causes each of the cordends to be moved into engagement with a workholder at a cord-transferposition. Then the workholder is caused to be moved pivotally toposition each cord end in an assembly position in alignment with a hornand an anvil of ultrasonic bonding facilities. Priorly, mating plasticparts which are to comprise the plug housing have been fed to theassembly position with one of the parts vacuumly held by the horn andthe other part supported on the anvil. Facilities are operated to removea jacket from an end portion of the cord and expose individuallyinsulated conductors. The anvil is raised to cause the exposedconductors to be positioned in associated ones of conductor-receivingtroughs formed in the other part supported on the anvil and the hornmoved downwardly to engage and bond the one part with the other part.Then insertion rams are actuated to move a plurality of blade-liketerminals along individual passageways in the anvil and to insert theterminals in terminal-receiving grooves in each of the other parts andto engage electrically the conductors received therein. Excess lengthsof conductors extending beyond the plug are severed and ejected afterwhich the workholder is returned pivotally to the cordtransfer positionwhereat the cord end is released from the workholder. A die is moved inone direction transversely of the anvil to align slots in the die withthe passageways in the anvil. A plurality of strips of terminals areadvanced to position a leading, partially formed, terminal in each stripin an associated partially enclosed passageway in the anvil. Then thedie is moved in a direction opposite to the one direction to sever theleading portion of each strip to form a terminal and to complete theenclosure of the passageways in the anvil in preparation for anothercycle of operation.

BRIEF DESCRIPTION OF THE DRAWINGS Other objects and advantages of theinvention will appear from the following detailed description of aspecific embodiment thereof when read in conjunction with theaccompanying drawings in which:

FIG. 1 is a perspective view of a retractile telephone cord having amoldular plug assembled to each end thereof;

FIGS. 2, A to J, are a sequence of perspective views of the steps of amethod embodying the principles of this invention for assembling theplugs to the cord;

FIG. 3 is a front elevation view of an apparatus for assembling a plugto each end of a cord;

FIG. 4 is a side elevational view of the apparatus of FIG. 3;

FIG. 5 is a plan view of the apparatus of FIG. 3;

FIG. 6 is an enlarged plan view of a transfer device into which anoperator positions one end of a cord and a workholder to which the cordend is transferred;

FIG. 7 is an end elevational view of the transfer device;

FIGS. 8 and 8A are enlarged plan views of the workholder shown in acord-transfer and in an assembly position;

FIG. 9 is a front elevational view of a portion of the apparatus forfeeding a base and a top portion of each plug into an assembly position;

FIG. 10 is a detail view of a portion of the workholder;

FIG. 11 is a detail view of the relative positions of the base, top andstripped cord end prior to assembly;

FIG. 12 is an enlarged view of the workholder and facilities forremoving scrap material therefrom;

FIGS. 13A 13E are a sequence of views of the workholder shown in theassembly position and showing the stripping of a portion of the cordjacket to expose individually insulated conductors;

FIG. 13F is side elevational view showing the workholder and analternate embodiment for removing the stripped jacket and excess lengthsof conductors which have been severed;

FIG. 14 is a perspective view of a portion of the apparatus forcompleting the forming of terminal blades and inserting same into a plugtop and into electrical engagement with the conductors positionedtherein;

FIG. 15 is a side elevation view of the terminal insertion facilities;

FIGS. 16 and 17 are enlarged views of a die used to form the terminalblades;

FIGS. 18 and 19 are enlarged views showing the insertion of the terminalblades;

FIGS. 20 and 21 are enlarged views of a device for severing the excessends of conductors extending beyond a front end of the assembled plug;

FIG. 22 is an electrical control circuit for the assembly apparatus; and

FIG. 23 is a schematic view showing a pneumatic control system for theassembly apparatus.

DETAILED DESCRIPTION Product Description Referring now to FIG. 1, thereis shown a retractile telephone cord, designated generally by a numeral50, which includes coiled cordage 51 having a plug 52 assembled to eachend thereof in accordance with the principles of this invention. Thecoiled Cordage 51 includes a plurality of individually insulatedconductors 53-53 (see FIG. 2E) enclosed by ajacket 54. The plug 5 52 iscomprised of two mating parts 56 and 57 which are bonded togetherultrasonically and which are referred to as the base and the top,respectively. The part 57 has a plurality of conductor-receiving troughs5858 (see FIG. 18) for receiving associated ones of the conductors 53-53and with which electrical contact is made by associated ones of aplurality of terminal blades 59-59 which are inserted interminalreceiving grooves 61-61 (see FIG. 18) formed in the part 57 andwhich communicate with the troughs 5858. The plug 52 also includes aledge 62 (see FIG. 11) protruding beyond the troughs 58-58 as well asother features disclosed and claimed in US. Pat. Nos. 3,699,498 and3,761,869.

20 Overall Apparatus An apparatus for assembling one of the plugs 52-52to each end of a retractile cordage 51 is shown in FIGS. 3, 4 and 5 andis designated generally by the numeral 70. The apparatus 70 includesdual assembly positions and assoicated facilities for assemblingsimultaneously one of the plugs 52-52 to each cord end. As is seen inFIG. 3, these are designated Assembly Position Nos. I and II. Only oneof each of the duplicate facilities, specifically those associated withAssembly Position No. I, will be described.

The apparatus 70 includes a transfer device, designated generally by thenumeral 71 (see FIGS. 4 and 5) for receiving an unfinished cord end at acord-input position and for transferring the cord end at a transferposition to a workholder, designated generally by the numeral 72. Theworkholder 72 is moveable between the cord-transfer position and aplug-assembly position whereat the cord end is aligned with two spacedaligned mating parts 56 and 57 which have been moved thereto by feedingfacilities, designated generally by the numeral 73.

Also, as can best be seen in FIG. 3, the apparatus 70 includes bondingfacilities, designated generally by the numeral 74, for bonding togetherultrasonically repetitively associated aligned mating parts 56 and 57 inthe assembly position. The apparatus 70 is also provided with insertionfacilities, designated generally by the numeral 76 (see FIG. 4), forcompleting the forming of partially formed terminals 59-59 and forinserting the terminals in associated ones of the terminal-receivinggrooves 61-61 into the part 57.

All of the facilities described are supported by associated elements offramework, designated generally by the numeral 77 which is supported ina base 78.

In order to best described the apparatus 70 and the operation thereof,reference will be made to FIGS. 2A2.I as each portion of the apparatusand its function is described. This will correlate the function of eachportion of the apparatus to the product at various phases in theassembly thereof. Following the completion of the description of theapparatus, a cycle of operation will be described with reference tofacilities for controlling that operation.

Transfer Device In order to initiate the operation of finishing a cord51 by assembling a plug 52 to each end thereof, the apparatus includesthe transfer device 71 (see FIG. 6) which has provisions for acceptingunfinished ends of the cordage from the operator at the cord-inputposition and for transferring the cordage to the workholder 72 at thecord-transfer position (see FIG. 2A). Viewing FIG. 2A, it should benoted that the cordage 51 shown in the phantom position is in thecord-input position, and the cordage in solid is in the cord-transferposition. Further, the right-hand side of the cordage 51 is associatedwith Assembly Position No. I, and the left-hand side with Position No.II.

Referring now to FIGS. 6 and 7, it can be seen that the transfer device71 includes a crank 101 connected to a hub 102 mounted on a shaft 103 ofan air motor 104 supported from a frame 106. The crank 101 is moveableby the air motor 104 cyclically between the associated cord-inputposition and the associated cordtransfer position.

Still referring to FIG. 6, it can be seen that the crank 101 has aloading bar 107 cantilevered therefrom for holding a cord end. In orderto accomplish this, the loading bar 107 is formed with a plurality ofspaced U- shaped fingers 111, 112, 113 and 114 into which an operatorpositions an end portion of the unfinished cordage 51. At the time thetransfer device 71 receives an end of the cordage 51 from the operator,the transfer device is in the cord-input position shown in solid linesin FIG. 7.

The transfer device 71 includes provisions for conditioning portions ofthe workholder 72 for each cycle of operation. Referring to FIG. 7, itmay be seen that a bracket 116 is attached to and extends from the frame106. The bracket 116 has a stud 117 extending therefrom. When theworkholder 72 is returned to the cordtransfer position from theplug-assembly position, the stud 1 17 engages portions of the workholderand as will be described hereinafter in detail, and causes theworkholder to be conditioned for the next cycle of operation.

workholder The workholder 72 may best be seen by referring to FIGS. 6-9and is designed to accept the unfinished cord end from the transferdevice 71 at the cord-transfer position (see FIG. 2A), turn the cord endthrough an angle of approximately 90 (see FIGS. 2D and 8) into the plugassembly position, and to hold the cord end while a portion of thejacket is separated (FIG. 2E), the plug 52 assembled thereto (see FIG.2G), the terminals 59-59 inserted (see FIG. 2H), and excess lengths ofthe conductors 53-53 severed and ejected (see FIG. 21) together with theportion of the jacket.

As can best been seen in FIGS. 6, 8 and 9, the workholder 72 issupported from a column 131 mounted in the framework 77. In order toturn the workholder 72, a link 132 is connected at one end thereof tothe column 131 and has the other end thereof pinned to a linkage bar 133which is pinned at the other end thereof to a toggle 134. The toggle 134is attached to a forward end (nearest the operator position) of a pistonrod 136 extending from a cylinder 137.

In the position shown in FIG. 6 with the piston rod 136 withdrawn intothe cylinder 137, the workholder 72 is in the cord-transfer position(see FIGS. 2B and 2C and also broken line position in FIG. 8). In thesolid line position shown in FIG. 8, the piston rod 136 is extended toturn the linkage bar 132 in a counterclockwise direction to move theworkholder to the plugassembly position (shown in solid lines in FIG. 8and also seen in FIG. 2D).

The workholder 72 includes a bifurcated member 141 (seen best in FIGS. 8and 9) with pivotally mounted stud 142 supporting a cam follower 143between the armsthereof. The stud 142 is biased to the left as shown inFIG. 9 by a spring 144. Also received between the arms of the bifurcatedmember 141 is a bar 146 which supports a cam follower 147. The camfollower 1467 is biased in a downward or clockwise direction about a pin148 by a spring 149.

When the workholder 72 is in the cord-transfer position, the cams 143and 147 are not in engagement with fixed camming surfaces 151 and 152,respectively (see FIG. 8A). Hence, when the transfer device 71 is turnedin a clockwise direction as shown in FIG. 7, the cord 51 is caused to beurged into engagement with undersides l53153 (see FIG. 9) of the arms ofthe bifurcated member 141. The bar 146 is urged upward against theaction of the spring 149. Similarly, the spring 144 is overcome and thestud 142 is urged rearwardly slightly to permit entry of the cordage 51(see FIG. 9).

Then, when the workholder 72 is rotated through the quarter angle, thecams 143 and 147 are caused to engage the fixed cam surfaces 151 and152, respectively (see FIG. 8A), to cause the member 146 and stud 142 tosecure the cordage 51. This prevents slippage of the cordage 51 duringthe subsequent assembly and stripping operations. The partial locking ofthe cordageSl by the follower 147 is as shown in FIG. 13A.

AT this time attention should be directed to still another cam.Referring now to FIG. 8A, it can be seen that a cam is biased to theleft by a spring 150 and in engagement with the cam follower 143. Thecam 145 and spring 150 are mounted on the general framework 77.

Following the transfer of the cordage end into the workholder 72 andtransfer of the plug parts 56 and 57, the rotational movement of theworkholder into the phantom line position shown in FIG. 8A causes thecam follower 143 (in position 143a in FIG. 8A) to urge the cam 145 tothe right. When the workholder 72 is in the phantom line plug-assemblyposition shown in FIG. 8A, the cam follower 143 assumes the position143b in engagement with the cam 151 to secure the cord as hereinbeforedescribed. It should be observed that once the cam follower 143 movesout of engagement with the cam 145, that cam is biased to the left asviewed in FIG. 8A into the position 145a.

The cam 145 has the primary function of causing the cordage 51 to bereleased from the workholder 72 which the workholder is returned to thecord-transfer position. As the workholder 72 is rotated clockwise asviewed in FIG. 8A, the cam follower 143 rides along an opposite face ofthe cam 145 (see position 1430). This causes the spring 144 to beovercome and the stud 142 (see FIG. 9) to be turned in a clockwisedirection to remove the clamping forces applied to the cordage. Thefinished cord end is permitted to descend by gravity from the workholder72 into a collection bin (not shown).

With the cordage 51 now securely held within the workholder 72 and afterthe workholder has been rotated into the solid line position shown inFIG. 8 by the operation of the cylinder 137, the apparatus 70 functionsto remove a predetermined length of the jacket 54 to expose theindividually insulated conductors 53-53. This will permit the subsequentengagement of the conductors 5353 with the conductor-receiving troughs5858 of the part 57 prior to the bonding step. Although the strippingfacilities will now be described, it should be realized that this stepdoes not occur until the workholder 72 has been rotated and this doesnot occur until parts 56 and 57 have been transferred into theplug-assembly position.

Referring now to FIGS. 6-9 and 12-13A, it can be that the workholder 72includes a U-shaped stripping head 153 which includes opposed cuttingblades 154-154 (best seen in FIG. 13A) held within a notch formed in aleg 155 thereof. The other leg 156 of the stripping head 153 is V-shapedand is designed to hold securely the cordage 51. The head 153 is mountedslidably on a rod 157 which is connected to the column 131 and extendsrearwardly of the operator to a cross head 158.

As can be seen in FIG. 8, the crosshead 158 has a latch 159 mountedpivotally thereto and spring-biased in a clockwise direction as viewedin FIG. 8. The latch 159 includes a toothed end 161 and a release end162. Whebn the workholder 72 is returned to the cordtransfer positionfrom the plug-assembly position, the release end 162 of the latch 159engages the stud 117 (see FIG. 7). This overcomes the spring-bias andcauses the latch to be moved pivotally in a counterclockwise directionas viewed in FIG. 8.

The stripping head 153 is spaced from the bifurcated member 141 by astop 163 and a gauging button 164. The stop 163 is attached to thebifurcated member 141 while the button 164 is attached to the strippinghead 153. The crosshead 158 is attached to the stripping member 153through a dowel 169 connected to a hub 165 having a flanged end 166. Ascan best be seen in FIG. 8, a compression spring 167 is disposedconcentrically about the dowel 169 to bias the interconnected hub 165,stripping head 153 and button 164 into engagement with the stop 163.

Feeding and Positioning Plug Parts Although reference has been made toones of the drawings which depict the workholder 72 in the plugassemblyposition, it should be noted that this was done because of theintroduction of the workholder at that point in the description of theapparatus 70. Again it should be emphasized that the workholder 72 isnot moved into the plug assembly position shown in solid lines in FIG. 8until leading ones of the parts 56 and 57 have been moved into theplug-assembly position.

This can be observed from a study of FIGS. 2A-2D. In FIG. 2A, the parts56 and 57 have not yet been fed into the plug-assembly position. This isaccomplished in FIGS. 2B-2C while the cordage ends are being transferredfrom the transfer device 71 to the workholder 72.

Referring now to FIGS. 3 and 4, it can be seen that the feedingfacilities 73 associated with each assembly position includes vibratorysupply hoppers 171 and 172. The hoppers 171 and 172 have feed tracks 174and 176, respectively, extending therefrom to plugtransfer positions(see FIG. which are aligned in one direction (see FIG. 4) with thebonding facilities 74.

The track 174 feeds one of the parts 56-56 in seriatim into a nest 177(see FIG. 10) formed in a block 178 of a transfer device, designatedgenerally by the numeral 179. The block 178 is moveable reciprocally byan air operated cylinder 181 which is best seen in FIG. 4. The block 178is supported on a slide 182 supported within a housing 183. As can beseen in FIG. 10 one end of the slide 182 is attached to a crossbar 184.The crossbar 184 is attached to a piston rod (not shown) extending fromthe cylinder 181 attached to the housing 183.

The transfer device 179 also has provisions for moving the block 178 andpart 56 supported therein upwardly. The housing 183 is supported from abeam 186 which may be moved upwardly by a pneumatically operatedcylinder 187 supported on a column 188. In an unoperated condition, thehousing 183 is supported on shoes 189189 resting in engagement with pads191-191 of a transfer device, designated generally by the numeral 192.

Similarly, the track 176 performs a gravity feed function of successiveleading ones of the parts 57-57 into engagement with the transfer device192. Simultaneously with the feeding of the parts 56-56, each successiveleading one of the parts 57--57 is fed along the track 176 to move aleading one thereof into a nest formed in one end of a block 193 of thetransfer device 192. As is seen in FIG. 10, the part 57 is held withinthe nest formed in part by a top surface 194 of a springbiased plate 195and a clamping member 196 connected to one end of a toggle bar 197.Another end 198 of the toggle bar 197, mounted pivotally about a pin199, is drawn to the left by a piston rod 200 withdrawn into apneumatically operated cylinder 201. This causes the bar 191 to beturned in a counterclockwise direction as viewed in FIG. 10 to cause theclamping member 196 to clamp and hold the part 57.

The transfer device 192 includes a housing 202 having a slide 203supported therein. One end of the slide 203 is attached to the block 193and the other end to a crossbar 204. The crossbar 204 also is connectedto a piston rod 206 (see FIG. 4) extending from a pneumatically operatedcylinder 207 supported laterally of the housing 202.

After the leading ones of the parts 56 and 57 in the tracks 174 and 176,respectively, are in the transfer devices 179 and 192, respectively, thecylinders 181 and 207 are operated to move the parts 56 and 57 to theleft as viewed in FIG. 10 and into vertical alignment with the bondingfacilities 74. Then the air cylinder 187 is operated to move the block178 upwardly to engage the part 56 with the contoured mating end of ahorn 209 of the bonding facilities 74. The horn 209 includes provision(not shown) for holding vacuumly each successive one of the parts 56-56.

The movement of the block 193 to the left is accomplished to positionthe part 57 in vertical alignment with an anvil 210 of the bondingfacilities 74. It should be noted that when the block 193 is moved fromits plug-transfer positions shown in FIG. 10, that the plate 195 engagesa side surface of the anvil 210. Further movement of the block 193causes the spring-bias of the plate 195 to be overcome therebyuncovering the bottom of the part 57 held by the clamping member 196.Hence, the part 57 is unsupported along a bottom face as it is movedover the anvil 210 but is held securely by the clamping member 196.Moreover, the clamping member 196 is longitudinal of the plane of thedrawings so that the toggle bar 197 and associated

1. A method of assembling one dielectric part with another dielectricpart about an end portion of a jacketed cord such that blade-liketerminals receivable in a plurality of terminalreceiving grooves in theone part establish electrical contact with conductors in the cord, whichincludes the steps of: inserting an end portion of the cord into aworkholder; moving leading ones of pluralities of the dielectric partsalong separate paths into vertical alignment with each other in anassembly position; moving the workholder to position the cord conductorsthereof in essentially vertical alignment with the grooves in the onepart; exposing the portions of the conductors in alignment with thegrooves while maintaining the alignment; moving the dielectric partsinto engagement with each other and with the cord such that theconductors are received within the grooves; bonding together thedielectric parts at a bonding position to form a dielectric housing; andmoving terminals into the grooves while the housing is in the bondingposition to seat the terminals in the housing to complete the assemblyand establish electrical contact with the aligned conductors.
 2. Amethod of assembling a plug comprised of a base and a top, the tophaving a plurality of conductor-receiving troughs and a plurality ofassociated terminal-receiving grooves aligned and communicating with thetroughs with an end portion of a multi-conductor cord such thatblade-like terminals receivable in the grooves establish electricalcontact with conductors in the cord, which includes the steps of:advancing strips of partially formed terminals connected end to end tomove a leading one thereof into insertion positions aligned with thegrooves in the top; confining a leading edge and two side surfaces ofeach leading one of the terminals; shearing the leading one of thepartially formed terminals from each of the strips to define and produceindividual terminals each having a trailing edge; while confining theleading ones of the terminals along the trailing edges thereof tosupport completely laterally the terminals and provide a laterallyclosed path of movement for the terminals; inserting an end portion ofthe cord into a transfer device; moving the transfer device to a cordtransfer position whereat the end portion of the cord is transferred toa workholder; applying clamping forces to the cord end to retain thecord end in the workholder; moving leading ones of a supply of bases andtops along separate paths into vertical alignment with each other into aplug assembly position; moving the workholder rotatably into the plugassembly position to align vertically the cord and conductors with thetroughs in the top; moving the base and the top into engagement witheach other and with the cord such that the conductors are received inthe troughs; bonding the top to the base; engaging a free edge of eachleading one of the terminals and then moving the terminals along thepaths into the aligned grooves and into electrical engagement with theassociated conductors therein; and returning the workholder to aninitial position and removing the clamping forces to release theassembled cord and plug from the workholder.
 3. The method of claim 2,wherein the cord includes a plurality of individually insulatedconductors enclosed by a jacket, which also includes: separating, thejacket of an end portion of the cord from the adjacent portion of thejacket to expose the individually insulated conductors; and severing,subsequent to the insertion of the terminals, excess lengths of theconductors protruding beyond the plug.
 4. The method of claim 3, whereinthe separating of the jacket of an end portion of the cord from theremainder includes: cutting circumferentially the jacket when the endportion of the cord is transferred to the workholder; and movingsubsequent to positioning the cord and conductors in vertical alignmentwith the base and top axially the jacket between the circumferential cutand the adjacent free end of the cord a distance less than the distancefrom the adjacent free end of the conductors to the circumferential cut;the movement designed to retain the severed jacket in engagement withthe ends of the conductors to maintain the conductors spaced apart tofacilitate receipt thereof into the troughs.
 5. An apparatus forassembling one dielectric part with another dielectric part about an endportion of a cord such that blade-like terminals receivable in aplurality of terminal-receiving grooves in the one part establishelectrical contact with conductors in the cord, which includes; aworkholder for holding an end portion of a cord; means for inserting anend portion of the cord into the workholder; means for moving leadingones of pluralities of the dielectric parts along separate paths intovertical alignment with each other in an assembly position; means formoving the workholder to position the conductor thereof in essentiallyvertical alignment with the grooves in the one part and for exposingportions of the conductors aligned with the grooves While maintainingthe conductors aligned with the associated grooves; means for moving thedielectric parts into engagement with each other and with the cord suchthat the conductors are maintained in alignment within the grooves;means for bonding together the dielectric parts at a bonding position toform a dielectric housing; and means operated while the bonding meansengages the parts for moving terminals into the associated grooves toseat the terminals in the housing to complete the assembly and establishelectrical contact with the aligned conductors.
 6. An apparatus forassembling a plug comprised of a base and a top, the top having aplurality of terminal-receiving grooves aligned and communicating with aplurality of conductor-receiving troughs with an end portion of amulti-conductor cord such that blade-like terminals receivable in thegrooves establish electrical contact with conductors in the cord, whichincludes: means for advancing a plurality of strips of partially formedterminals connected end to end to move leading ones thereof intoinsertion positions aligned with grooves in the top; means for confininga leading edge and two side surfaces of each leading one of theterminals; means for shearing the leading ones of each of the partiallyformed terminals from the strips to define and produce individualterminals each having a trailing edge and to confine the leading ones ofthe terminals along the trailing edges thereof to support completelylaterally the terminals and provide a laterally closed path of movementfor the terminals; a workholder including a shearing blade for holdingan end portion of the cord; a transfer device receiving and end portionof the cord for inserting an end portion of the cord into theworkholder, the transfer of the end portion of the end portion of thecord from the transfer device to the workholder causing the shearingblade to sever the jacket at a first distance from the free end of thecord to facilitate the subsequent removal of a portion of the jacketfrom the end portion of the cord; means for moving leading ones of asupply of bases and tops along separate paths into vertical alignmentinto a plug-assembly position; means for moving the workholder into theplug-assembly position to position the conductors thereof in essentiallyvertical alignment with the troughs in the top; means for moving thebase and the top into engagement with each other and with the cord suchthat the conductors are received in the troughs; means for bonding thetop to the base to form a dielectric housing; and means operated whilethe housing is in the plug-assembly position for engaging a free edge ofeach leading one of the terminals and then moving the terminals alongthe paths into the aligned grooves and into electrical engagement withthe associated conductors therein to complete the assembly of the plug.7. The apparatus of claim 6, wherein the subsequent moving of theworkholder into the plug-assembly position is rotational and further theworkholder includes: means for applying clamping forces to the cord endto retain the cord therein; means operated subsequent to the insertionof the terminal blades for returning the workholder to an initialposition; and means rendered effective as the workholder is returned tothe initial position for removing the cord clamping forces to releasethe cord from the workholder.
 8. The apparatus of claim 6, wherein thecord includes a plurality of individually insulated conductors enclosedby a jacket and, which also includes: means for separating, subsequentto the positioning of the cord in vertical alignment with the base andcover, the severed jacket of the end portion of the cord from theadjacent portion of the jacket to expose the conductors; means operatedprior to inserting the terminals for locking the bonding means inengagement with the dielectric housing; and means operated subsequent tOthe insertion of the terminals for severing excess lengths of conductorsprotruding beyond the housing.
 9. The apparatus of claim 8, wherein themeans for separating the jacket includes: means for moving axially thesevered portion of the jacket a second distance less than the firstdistance whereby the severed jacket maintains the conductors spacedapart to facilitate receipt thereof in the troughs.
 10. An apparatus forassembling mating dielectric parts to an end of a jacketedmulti-conductor cord and for providing electrical access to each of theconductors, which comprises: a transfer device for receiving anunfinished cord end; ultrasonic means including an aligned horn andanvil for bonding together mating dielectric parts; means for advancingin seriatim parts of mating dielectric parts into engagement with thehorn and the anvil which in an unoperated condition are spaced apart; aworkholder mounted rotatably for receiving the cord end from thetransfer device at a transfer position; means for causing the transferdevice to transfer the cord end to the workholder at a transfer positionand for operating the advancing means to transfer each leading one ofone of the mating parts to the anvil and the leading one of the othermating parts to the horn; means operated subsequent to the advancing ofthe mating parts for turning the workholder into an assembly position toposition the cord end in vertical alignment with the mating spacedaligned parts and for separating the jacket of an end portion of thecord from the adjacent portion of the jacket to expose the individuallyinsulated conductors of the end portion of the cord; means for movingthe horn and the anvil to mate the parts in engagement with the endportion of the cord and to bond together the parts; means for insertingterminals in grooves in the one part and into electrical engagement withthe conductors therein; means for severing excess lengths of the exposedconductors extending beyond the mated bonded parts; means for returningthe workholder to the transfer position; and means operated upon thereturn of the workholder to the transfer position for releasing the cordend.
 11. The apparatus of claim 10, wherein the workholder also includescord clamping means which upon rotation of the workholder into theassembly position is caused to clamp the cord end to facilitate removalof the jacket therefrom and which upon return of the workholder to thetransfer position is caused to release the cord end.
 12. The apparatusof claim 10, which also includes means operated subsequent to theconductor exposure and the conductor severance for removing a portion ofthe jacket and excess conductor lengths from the apparatus.
 13. Theapparatus of claim 10, wherein the anvil has a plurality of passagewaysaligned with the grooves in the one part to permit passage therethroughof the terminals into the one part, which also includes: means operatedsubsequent to the return of the workholder to the cord-transfer positionfor advancing incrementally each of a plurality of strips of terminalsto position leading ones thereof in the passageways in the anvil and forsevering leading ones of each strip in preparation for insertion thereofduring the next cycle of operation.
 14. The apparatus of claim 11,wherein the one part also includes a plurality of conductor-receivingtroughs aligned with associated ones of the grooves and the means forseparating the jacket includes: means for cutting circumferentially thejacket at a first distance from the free end of the cord; and means formoving axially the severed portion of the jacket a second distance lessthan the first distance to expose the conductors and to maintain theconductors aligned with the troughs.
 15. The apparatus of claim 14,which also includes means effective upon the return of the workholder tothe transfer position for conditioning the jacket removiNg means foranother cycle of operation.